Thermocouple structure



Jan. 25,1944. w. A. RAY

THERMOCOUPLE STRUCTURE I Filed March 1'7, 1941 INVENTOF? MOW/am A. P4 1 TT NE Patented Jan. 25, 1944 UNITED STATES PATENT OFFICE 'rnsmuocoma s'rnuc'ruar. William A. Ray, Glendale, Calif. Application March 17, 1941, Serial No. 383.695 scam (oi. 136-4) This invention relates to the generation of electrical energy by the aidof heat. Thermocouples for the conversion of heat energy into electrical energy have been used and are now well known. They depend for their operation uponapplying heat at a hot junction between dissimilar metals. differential between the hot junctiorr'and the cold junctions forming the terminals of the metals,

the greater the amount of electrical energy generated.

Such thermocouple structures are now com--- monly used in control systems as for fuel burner The greater the temperature apparatus. For example, the'hot junction of the thermocouple may be arranged to be influenced by the flame of a pilot burner. When the flame is extinguished, the generation of electricity ceases, and control devices are caused to function y in response to the cessation of flow of electrical For example, a valve controlling the energy. supply of fuel to the main burner may be caused to close. The thermocouple structure must be made as to be capable of resisting the high temperatures of the flame without serious deterioration, and the electrical energy generated must be sum cient topermit such control functions to be obtained.

. It is one of the objects of this inventionto make" it possible to, obtain these useful results by the aid of an inexpensive and simple structure.

Suitable materials for the dissimilar metals forming the thermocouple, that can withstand the high temperatures are such alloys as Chrome! and Copel. These however'are quite expensive and accordingly it is desirable to reduce the sheathed thermocouple is shown and claimed in Patent No. 2,289,455 dated July 14, 1942, :in the name of William A. Ray and-entitled: Thermocouple structure. The present invention also involves the use of a casing, which is so arranged that it does not impede flame travel. The casing has a tip that is uniformly heated, resulting in freedom from cold spots. The exterior area of the sheath or casing that is subjected to the is a Jet 3.

flame is quite large, ensuring eflicient fer to the hot junction.

This invention possess many other'advantages, and has other objects which may be made morew easily apparent from a consideration of one em-'- bodiment of the invention. For this purpose there is shown a form in the drawing accompanying and forming part of the present specification. This form will now be described in .detail, illustrating the general principles of the invention; but it is to be understood that this detailed description is not to be taken in a limiting sense,

heat trans-- since the scope of this inventionis best defined by the appended claims.

Referring to the'drawing: 1

Figure 1 is. a side elevation of a thermocouple structure incorporating the invention, shown as used with a pflot burner;

Fig. 2 is 'an enlarged side elevation, -partly broken away, of a'thermocouple structure incorporating the invention;

Fig. 3 is a longitudinal sectional'view taken along plane 3-3 of Fig. 2;

Figs. 4 and 5 are sectionalviews taken along planes 4-4 and 55 of Fig. 2; and

Fig. 6 is a pictorial view of one of the elements of the structure.

In Figure 1- the pilot burner l is shown as a vertically extending pipe adapted to be connected to a source of fuel as by the aid of the conduit 2. At the upper end ofthe burner I there This jet. may be provided with diametrically opposite'openings such as-indicated by the reference character 4, from which pilot flames 6 and 8 may issue. Connecting thegflames 5 and 6 is an igniting flame 1 adapted to issue from an appropriate narrow passageway across the V top of jet 3, so as'to ensure that thepilot flames 5 and 8 may be simultaneously ignited.

The thermocouple structure 8 incorporating the invention comprises a metallic sheath orcasing Y including the halves 9 and I0 (Figs.'2, 3, 4. and 5) These halves or shells may be made from thin stainless steel; and upon assembly the contact ing flanges along the edgesii and i2 may be welded together as by stitch welding. This welding. is indicated diagrammatically by the dotted lines l3 of Fig. 2.

The casing'formed of the halves 9 and I0 is arranged to be so supported that its upper end is inserted within the flame 5. Thissupport is so arranged furthermore that th flame 5 extends around the shell 9l 0, the casing being presented edgewise to the flame. The flame 5 streams naturally around the shell, which forms 1ittle-resistance to the flame travel. There is thus no substantial likelihood of any cold spots adjacent the hot junctions.

One manner in which the thermocouple structure 8 may be thus supported is illustrated in Fig. 1. A bracket structure 14 which may comprise two halves, is arranged to encompass the burner I .as well as the lower portion of the thermocouple structure 8. A bolt or screw l4 holds the two halves of the bracket structure together so as to clamp the burner l and the thermocouple structure 8 between them.

The thermoelectric conductors in this case comprise the conductors l and I8. These are 01 dissurface of the end l8. Preferably the convolutionsll are fused to the endlil. The hot. junction of the thermocouple struc- 20, 2|, the be slightly flared outwardly as indicated at 21.

The manner of assembly of the thermocouple structure is clear from the foregoing. The conductors l5 and I6 are first assembled as in the form illustrated and the copper lead 28 is Joined to the end oi the Chromel conductor IS. The refractory insulation sleeves --2| may then be applied and the thermocouple structures laid into one of-the-two casing halves 9 or ill. -Tlhe other casing half may then be disposed over the first casing half and the flanges 24 stitch welded together.

iDue to the bulbous enlargement at the upper end of the thermocouple structure there is no danger that the device 9-40 be inadvertently pulled of! from the conductors. 'The conductors are flrmlyheld between the casing halves.

ture therefore includes the convolutions I! about I I the end i8, which forms a, central core for these convolutlons. Heat istransmitted to this hot junction by-conduction through the wall of the shell or casing 9-!0.

The conductors l5 and it are disposed side by side within the shell or casing 9-40 as shown most clearly in Figs. 2 and 5. These-conductors may be covered with a refractory insulation material such as sleeves 20 and 2| made from braided spun glass. The sides of the casing 8-H! closely encompass these. covered portions of the conductors l5 and I6. Furthermore, the insulation sleeves 20 and 2| extend substantially up to the oonvolutions i1.

For the accommodation 01' the convolutions I! each of the halves 9 and I0 carry deeper recesses 22 and 23 adjacent the top ends of the shells.

This is ind cated most clearly in Figs. 3, 4 and 6. The half casings as shown most clearly in Fig, 6

have the flat flan es 24 which are placed in contact and alonglwhich the stitch weld II may be The Chromel conductor I! may end within the sheath or casing 9'-lll as illustrated at the joint 25 (Fig. 2). A copper lead 2-6 may be joined to the end 25 and is shown as extending'downwardly out of the casing. The Copel conductor l6 may,

extend for a considerable distance to a point ofconnection outside the furnace chamber or into the cold air stream. such as secondary air. This may be-done without material loss of electrical energy. since the resistance of Copel wire is con-- siderably less than that of Chromel, out of which the conductor I5 is made.

Since the thermoelectric properties of copper and C-hromel are quite similar, the junction 25 does not' form. a thermoelectric cold junction at the joint 25. Efficient cold junctions are actually The flame 5 playing over the upper end of the thermocouple structure causes the casing 8-40 to be heated; and this heat is transmitted to the upper portions of the conductors I l and I6 forming the hot junction. The glass braided sleeves 20 and 2! and the casing 9-40 form a protection against undue transference of heat to the lower portions of the thermoelectric conductors.

What is claimedist' 1. In a thermal structure, a pair of thermoelectric conductors, the ends of said conductors being so joined electrically and mechanically that thejunction forms an enlarged end for the structure, refractory insulation material disposed over other parts of the conductors, and ametal shell disposed over and covering the hot junction, and in thermal contact therewith, ,said shell extending beyond the hot junction over the conductors,said shell having an enlarged recess for accommodating the enlarged end, said recess cooperating with said enlarged end to retain said structure in the shell.

2. Ina thermocouple structure, a pair otthermoelectric conductors arranged side by side, the ends of the conductors beingbare, the end of;one conductor being wound about .the. end o1 the other conductor to provide; a mechanical and electrical joint and forming the hot junction; for

covering other parts of the conductors to a=pointadjacent said hot junction,- and a metalshellcovering the hot junction and'in-thermalgcontact therewith, said shell having an enlarged ,-lrecessfor accommodating the ends, and-cooperatingwith said ends .toretain said structuredn. the shell, said shell extending as ,well over at-le a part of the covered conductors.

3. In a thermocouple structure, a pair hithermoelectric conductors, the ends ofsaid conductors' being so joined electrically an amechanically that the junction forms an e' larged end for the structure, refractory insulation material disposed over other parts of the conductors,

and a longitudinally split shell formed of halves I each having a flange extending outwardly of the shell,-the flanges being joined to form the complete shell, said shell being in thermal contact formed at the ends of the copper lead 28 and the 4 Co'pel lead l6. These cold junctions, being located out of the furnace chamber or to the cold air stre'am,-'have temperatures considerably below,

that of the hot junction formed by the convolui tions I! and the end It. The glass braided sleeves 20 and 2! may extend for-a considerable distance beyond the bottom or the casing 8-". .-Fur-' ther more,-in order to avoid injury to the-braids 'with'the hot junctions, and having an enlarged recess at one end cooperating with the hot junction to retain said structure in the shell, the shell having a portion extending over covered portions of the conductors.

4. In a-thermocouple structure, a pair of conductors, ends of the conductors being joined to form a hotjunction portion occupying a space of greater crosssection than that required by'the lower edges of the casing 9 and may conductors placed side by side, refractory insulating material covering each conductor to a place adjacent said portion, and a metal shell in thermal contact with said hot junction and enclosing at least-a portion of said conductors as well as said hot junction portion, said shell having a reduced portion for accommodating the conductors as well as a recess for closely embracing said enlarged-portion, whereby said strucform'a hot junction portion occupying a space of greater cross section than that required by the conductors placed side by side, refractory insulating material covering each conductor to a place adjacent said portion, a, metal shell enclosing at least a. portion of said conductors as well as said hot junction portion, and in thermal contact therewith, said shell having a reduced portion for accommodating the conductors as well as a recess for closely embracing said enlarged portion, whereby said structure and the shell are retained in assembled relationship, one ofsaid conductors being relatively long and extending out of the shell for a. substantial distance, the other conductor being relatively short and terminating in the shell, and being-joined to a lead therein, said lead extending out of the shell for a substantial distance, the cold junctions for the structure being respectively at the outer ends of the lead and of the long conductor.

A. RAY. 

